Sensor-Based Pleat Counting for Accurate Air Filter Media Inspection

Solution Overview

Problem

Manual counting of pleats in corrugated sheets for air filter production is time-consuming and prone to errors, leading to potential production of faulty air filters.

Innovation Solution

A pleat counter system comprising a pleat detector with sensors mounted underneath a mounting board, which is configured to position the pleat detector adjacent to the corrugated sheet. The system translates the corrugated sheet past the pleat detector while remaining stationary, allowing for accurate counting of pleats and integration with a data processing system for real-time monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual counting of pleats is used, then device complexity is reduced, but productivity decreases and measurement precision deteriorates

Engineering Contradiction:

Improvecounting speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces the manual mechanical counting process with an automated optical sensing system. Sensors mounted on a scanning device detect pleats as the corrugated sheet passes by, eliminating the need for manual visual inspection and counting. This substitution dramatically increases counting speed and accuracy while reducing human labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service by allowing the scanning device with mounted sensors to automatically count pleats without human intervention. The device scans the corrugated sheet, detects pleat positions through sensors, and provides automated counting results, making the process independent of manual operation while maintaining high productivity.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If manual counting of pleats is used, then device complexity is reduced, but measurement precision deteriorates

Engineering Contradiction:

Improvepleat counting accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the manual mechanical counting process with an automated optical sensing system. Sensors mounted on a scanning device detect pleats as the corrugated sheet passes by, eliminating the need for manual visual inspection and counting. This substitution dramatically increases counting speed and accuracy while reducing human labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces sensors as an intermediary between the corrugated sheet and the counting process. These sensors detect pleat positions optically or electronically as the material moves through the scanning device, providing precise measurement data without requiring direct human contact or visual assessment, thereby improving accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of time

If manual counting of pleats is used, then device complexity is reduced, but loss of time increases

Engineering Contradiction:

Improvecounting timeVSAvoidsystem complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces the manual mechanical counting process with an automated optical sensing system. Sensors mounted on a scanning device detect pleats as the corrugated sheet passes by, eliminating the need for manual visual inspection and counting. This substitution dramatically increases counting speed and accuracy while reducing human labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The scanning device with mounted sensors continuously scans the corrugated sheet as it moves through the system, enabling uninterrupted pleat detection and counting. This continuous operation eliminates the stop-start nature of manual counting, significantly reducing the time required to count pleats across large areas of material.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The pleat counter system significantly reduces the time and likelihood of errors in counting pleats, ensuring accurate production of air filters and preventing faulty products from entering the market.

Implementation Method 1

The pleat detector includes one or more sensors configured to detect the presence of individual pleats comprising the corrugated sheet

Methodology Applied

Scientific EffectSensing:

Data Source

PatentUS20250045556A1Pleat Counter

Publication Date: 2025.02.06 K&N ENGINEERING INC

AI summary

A pleat counter and methods are provided to accurately count the number of pleats in a corrugated sheet of material to be used for the production of air filters. The pleat counter comprises a pleat detector mounted underneath a mounting board for counting the pleats. The mounting board is configured to position the pleat detector adjacent to the corrugated sheet of filter material. The pleat detector includes one or more sensors configured to detect the presence of individual pleats comprising the corrugated sheet. The pleat counter includes an interface configured to enable coupling the pleat counter with a data processing system. The data processing system may comprise any of a desktop, a tablet, a server, a mobile phone, a media player, a personal digital assistant (PDA), a personal communicator, a network router or hub, a wireless access point (AP) or repeater, a set-top box, or a combination thereof.